Method of forming collimated hole structure

ABSTRACT

A method of making a collimated hole structure wherein the passages have preselected non-regular cross sections defined by a composite of preselected regular sections. Examples of such nonregular cross sections are T, L, S, I, star, trilobal, and various non-symmetrical sections. The collimated hole structures are formed by constricting a plurality of rods having the regular section configuration laterally related to define the non-regular cross sectional configuration. The rods corresponding to the passage configurations are formed of a material differing from that of the other rods to permit removal thereof upon completion of the constriction operation whereby small size passages are formed having the desired non-regular cross section.

United States Patent [191 Roberts et al.

[54] METHOD OF FORMING COLLIMATED HOLE STRUCTURE [75] Inventors: John A. Roberts, North Chelmsford; Peter R. Roberts, Groton; Alwyn H. King, Sherborn; Lee B. Danzey,

[21] Appl. No.: 182,102

Related US. Application Data [62] Division of Ser. No. 701,774, Jan. 30, 1968, abandoned.

[52] US. Cl ..29/423, 29/157 C, 29/599, 29/D1G. 47 [51] Int. Cl. ..B23p 17/00 [58] Field of Search ..29/423,183,183.5,187.5, 29/157 C, DIG. 47, 599; 148/4; 204/1291, 129.35; 72/253, 254

[56] References Cited UNITED STATES PATENTS 2,149,905 3/1939 Zuckert ..40l/l7 2,499,977 3/1950 Scott ..29/423 X [451 Jan. 30, 1973 2,619,438 11/1952 Varian et al ..29/423 X 3,291,870 12/1966 Allison ..29/423 3,564,566 2/1971 Heitman ..29/423 3,591,915 7/1971 Roberts et al. ..29/423 3,673,667 7/1972 Lowenstein ..29/423 Primary ExaminerRichard l Herbst Assistant ExaminerV. A. Dipalma Attorney-Donald S. Olexa et al.

[57] ABSTRACT A method of making a collimated hole structure wherein the passages have preselected non-regular cross sections defined by a composite of preselected regular sections. Examples of such non-regular cross sections are T, L, S, 1, star, trilobal, and various nonsymmetrical sections. The collimated hole structures are formed by constricting a plurality of rods having the regular section configuration laterally related to define the non-regular cross sectional configuration. The rods corresponding to the passage configurations are formed of a material differing from that of the other rods to permit removal thereof upon completion of the constriction operation whereby small size passages are formed having the desired non-regular cross section.

9 Claims, 16 Drawing Figures PATENTEUmao I975 3.713.202

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PeZ'erZZZZabe Zee BDan W yo aii u yn/ L%SI METHOD OF FORMING COLLIMATED HOLE STRUCTURE CROSS REFERENCE TO CO-PENDING APPLICATION This application is a divisional application of our copending application Ser. No. 701,774 filed Jan. 30, 1968 now abandoned.

This invention relates to collimated hole structures and, in particular, to collimated hole structures of extremely small size and methods of forming the same.

In the Roberts and Roberts co-pending application for U.S. Pat., Ser. No. 471,123, filed July 12, 1965, for a Passage Structure, and owned by the assignee hereof, a collimated hole structure is disclosed to comprise a plurality of small passages in a metal matrix body. The passages are generally regular in cross section. The present invention comprehends an improved collimated hole structure generally of the type disclosed in said Roberts and Roberts application, but having a novel passage arrangement for use in many applications requiring a non-regular passage cross section. Reference may be had to the Roberts and Roberts application for a full disclosure of the general method of forming the collimated hole structure. The present invention comprehends a novel modification of the method disclosed in the Roberts and Roberts application as will be brought out more fully hereinafter. Thus, the present invention is concerned with an improved novel collimated hole structure and an improved novel method of forming the same.

A principal feature, therefore, of the present invention is the provision of a new and improved collimated hole structure including a body defining spaced surfaces and having a plurality of laterally spaced passages opening therethrough, the passages having preselected non-regular cross sections defined by a composite of preselected regular sections having a maximum cross section of under approximately 500 microns.

Another feature of the invention is the provision of such a collimated hole structure wherein the regular sections include polyhedral sections.

Still another feature of the invention is the provision of such a collimated hole structure wherein the nonregular cross sections comprise a T-shaped cross section.

Yet another feature of the invention is the provision of such a collimated hole structure wherein the nonregular cross sections comprise an L-shaped cross section.

A further feature of the invention is the provision of such a collimated hole structure wherein the non-regular cross sections comprise an l-shaped cross section.

A still further feature of the invention is the provision of such a collimated hole structure wherein the nonregular cross sections comprise an asymmetrical cross section.

A yet further feature of the invention is the provision of such a collimated hole structure wherein the nonregular cross sections comprise a star shaped cross section.

Another feature of the invention is the provision of such a collimated hole structure wherein the non-regular cross sections comprise a trilobal cross section.

Yet another feature of the invention is the provision of such a collimated hole structure wherein the passages open perpendicularly through at least one of the surfaces.

Still another feature of the invention is the provision of a new and improved method of forming a collimated hole structure having passages of non-regular cross section having the steps of bundling in a preselected pattern a plurality of rods having a regular cross section, preselected ones of the rods being formed of a material differing from that of the other rods for permitting separation thereof from the other rod material when desired, the preselected ones of the rods being disposed in the pattern in correspondence to a preselected nonregular passage cross section, constricting the bundle to reduce the rods to a preselected cross section and unify the other rods to form a substantially monolithic body, and removing the preselected ones of the rods to define passages in the body having the preselected cross section.

A further feature of the invention is the provision of such a method of forming a collimated hole structure wherein the rods are bundled by endwise insertion into a tubular outer sheath.

A still further feature of the invention is the provision of such a method of forming a collimated hole structure wherein the preselected ones of the rods are unified by the constriction to define a continuous passage cross section upon removal thereof from the body.

A yet further feature of the invention is the provision of such a method of forming a collimated hole structure wherein the bundle is constricted by drawing.

Another feature of the invention is the provision of such a method of forming a collimated hole structure wherein the rods are bundled by endwise insertion into a tubular outer sheath and spacers are inserted between the outermost rods and the sheath.

Still another feature of the invention is the provision of such a method of forming a collimated hole structure wherein the spacers are formed of the same material as the other rods to become unified therewith and form a portion of the body.

Yet another feature of the invention is the provision of such a method of forming a collimated hole structure wherein the bundle includes an outer sheath formed of the same material as the other rods to become unified therewith and form a portion of the body.

A further feature of the invention is the provision of such a method of forming a collimated hole structure wherein the preselected ones of the rods are removed from the body by dissolution.

A still further feature of the invention is the provision of such a method of forming a collimated hole structure wherein the structure is cut to define spaced surfaces through which the passages open in the formed collimated hole structure.

A yet further feature of the invention is the provision of a new and improved spinnerette for use in forming a coalesced filament, comprising a body provided with a passage defining an extrusion orifice having a nonregular cross section defined by a composite of preselected regular sections having a maximum cross section of under approximately 500 microns.

Still another feature of the invention is the provision of such a spinnerette wherein the orifice has a T-shaped cross section.

Yet another feature of the invention is the provision of such a spinnerette wherein the body includes an FIG. 1 is an isometric view of an assembly illustrating a first step in the formation of the collimated hole structure of the invention;

FIG. 2 is a fragmentary isometric view of a number of different rod elements which may be used in the method of the invention;

FIG. 3 is a schematic side elevation illustrating a further step in the forming of the collimated hole structures;

FIG. 4 is a schematic side elevation illustrating a cutting step in formation thereof;

FIG. 5 is a schematic elevation illustrating a leachin step in the formation thereof;

FIG. 6 is an isometric view of a collimated hole structure embodying the invention;

FIG. 7 is a schematic side elevation illustrating a cutting step in the forming of a modified form of collimated hole structure embodying the invention;

FIG. 8 is an isometric view of another form of collimated hole structure embodying the invention;

FIG. 9 is an isometric view of still another form of collimated hole structure embodying the invention as made by the method including the step of FIG. 7;

FIG. 10 is a front elevation of a spinnerette formed with collimated hole structures embodying the invention;

FIG. 1 l is a diametri'c section of the spinnerette as installed in an extruding device;

FIG. 12 is a fragmentary plan view of an assembly of similar size rectangular rods as the first step in the forming of one form of collimated hole structure embodying the invention;

FIG. 13 is a fragmentary plan view of an assembly of different size rectangular rods and square rods as the first step in the forming of another form of collimated hole structure embodying the invention;

FIG. 14 is a fragmentary plan view of an assembly of similar size triangular rods as the first step in the forming of still another form of collimated hole structure embodying the invention;

FIG. 15 is a fragmentary plan view of an assembly of different size triangular rods as the first step in the forming of another form of collimated hole structure embodying the invention; and

FIG. 16 is a fragmentary plan view of an assembly of different size triangular rods as the first step in the forming ofostill another form of collimated hole structure embodying the invention;

In the exemplary embodiment of the invention as disclosed in the drawing, new and improved collimated hole structures, such as collimated hole structures 10 shown in FIG. 6, collimated hole structure 11 shown in FIG. 8, and collimated hole structure 12 shown in FIG. 9, are formed by a new and improved method to define passages having preselected non-regular cross sections made up of a composite of preselected regular sections. The method may be generally referred to as utilizing a building block technique wherein the rods are inserted endwise into an assembly, generally designated 13, such as shown in FIG. 1 in the desired arrangement.

More specifically, the first step in the novel method of forming the collimated hole structures comprises inserting rods such as square rod 14 shown in FIG. 1, rectangular rod 15, triangular rod 16, hexagonal rod 17 as shown in FIG. 2, as well as other suitable cross section rods, into a tubular can, or sheath, 18 in parallel side-by-side relationship. The resultant collimated hole structures l0, l1 and 12 are provided with through passages 19, 20, and 21, respectively, which are formed as a result of the placement of rods of different characteristics in the assembly 13 in the desired arrangement corresponding to the passages. Thus, for example, with reference to FIGS. 1 and 6, certain square rods 22 are inserted in the assembly 13 in combination with the square rods 14 to define the pattern, generally designated 23, which may be seen to correspond to the configuration of the passage 19 in the collimated hole structure 10. Rods 22 are formed of a material which differs from that of the rods 14 permitting the rods 14 to be subsequently removed from the assembly while leaving the material of rods 22. Thus, illustratively, rods 22 may be formed of stainless steel and rods 14 may be formed of monel metal.

The rods are inserted in the can 18 in relatively close fit with only sufficient clearance therebetween to permit sliding of the rods relative to each other to form the assembly 13. As shown, segmentally cylindrical spacers 24 may be provided to define a substantially hexagonal arrangement of the rods and a number of triangular rods 16 may be provided to fill in the gaps between the square rods 14 and 22 and the spacers 24 to provide an effectively voidless assembly 13.

The assembly 13 is then constricted to produce a final resultant small diameter composite 25 wherein each of the rods is correspondingly reduced in size and diffusion bonded to the adjacent rods and spacers to form a substantially monolithic composite 25. Illustratively, the spacers 24 and can 18 may be formed of the same material as rods 22, herein illustratively stainless steel, whereby the can 18 is unified with the spacers 24 to form a portion of the monolithic composite stainless steel matrix in which the monel rods 14 are disposed.

The constriction of the assembly 13 may be by any suitable constriction methods. Herein, the constriction is illustrated as being effected by drawing the assembly 13 through a series of progressively smaller drawing dies 26, 27 and 28. As will be obvious to those skilled in the art, any suitable number of constriction steps may be employed to provide the final reduced composite The composite 25 may then be cut transversely by suitable means such as cutting knife 29 to provide disclike elements 30. The elements 30 may then be treated suitably to remove the rod 14 material therefrom as by placing the elements in a suitable acid bath 31. In the illustrated embodiment, the acid bath may comprise a nitric acid leaching bath serving to dissolve the monel material and leave the stainless steel matrix body to define the collimated hole structure 10 shown in FIG. 6. Thus, the diffusion bonding of the rods 14 to each other provides a laterally extended passage configuration as a result of the combining of a plurality of the individual regular rods in the desired non-regular configuration.

Further, illustratively, the cross shaped passage 20 of FIG. 8 may be obtained by providing the monel rods 14 as square shaped rods with five such rods being installed in the assembly 13 in a juxtaposed cross shaped arrangement. As a result of the constriction process, the five rods become bonded together to define a cross shaped filament in the composite 25 which when leached in the acid bath 31 leaves the cross shaped passage 20.

The knife 29, as shown in FIG. 4, is arranged to cut the composite 25 substantially perpendicular to the axis thereof. The passages 19 of the collimated hole structure opens perpendicularly through the end surfaces 32 and 33 thereof. As shown in FIGS. 7 and 9, an angular disposition of the passage 21 may be provided relative to the surfaces 34 and 35 of the collimated hole structure 12 by the arranging of knife 29 at an angle to the axis of the composite 36. Thus, as shown in FIG. 9, the passage 21 extends obliquely through the matrix body 37 rather than coaxially therethrough as in the collimated hole structure 11 of FIG. 8.

Referring now to FIGS. 12 through 16, modified arrangements of the rods forming the original assembly are illustrated. Thus, in FIG. 12, a plurality of rectangular monel rods are shown to be assembled with a plurality of rectangular stainless steel rods 38. Rods 15 are arranged in T-shaped composite configurations to define a plurality of T-shaped passages in the collimated hole structure. In FIG. 13, relatively large stainless steel rectangular rods 39 are alternated with smaller stainless steel rectangular rods 15 and square stainless steel rectangular rods 14' to provide a composite matrix portion with similar relatively large monel rectangular rods 40, medium size monel rectangular rods 38, and small size monel rectangular rods 41 arranged to define a desired composite having the desired configuration of the passages of the collimated hole structure.

In FIG. 14, the arrangement of rods is shown to include six monel triangular rods 16 arranged in an hexagonal configuration with the intermediate rods comprising stainless steel triangular rods 42. Thus, the resultant passage structure would be one wherein the passages are hexagonal in cross section.

In FIG. 15, a Y-shaped trilobal arrangement of monel triangular rods 16 is shown to be arranged about an hexagonal arrangement of larger stainless steel triangular rods 43. In FIG. 16, the trilobal arrangement of monel rods 16 is similar to that shown in FIG. 15, but the arrangement of the stainless steel triangular rods 43 is made to be different so as to arrange the Y-shaped monel rod configurations in row alignment rather than around an hexagonal stainless steel portion.

The illustrations of FIGS. 12 through 16 are exemplary only as indicative of the many possible building block arrangements which may be utilized in conformity with the invention. The specific arrangement of the rods may be as desired by the user to obtain any desired passage configuration in the collimated hole structure.

One example of the use of the non-regular passage configuration is illustrated in FIGS. 10 and 11 wherein collimated hole structures 44 are mounted in a circular plate 45 to define a spinnerette, generally designated 46. The spinnerette may be mounted in a suitable duct 47 for conducting coalescible plastic material therethrough to form filaments 48. As shown, the collimated hole structures 44 comprise structures having a plurality of T-shaped passages 49 which are inclined to the surfaces 50 and 51 of the collimated hole structures in the manner of collimated hole structure l2 shown in FIG. 9. Thus, by orienting the collimated hole structures so as to have the leg of the T face the axis 52 of the plate 46, the filaments 48 are delivered towards the axis as they emerge downwardly from the lower surface 50 of the collimated hole structures, thus forming a multi-strand extrusion wherein the strands have T- shaped cross sections. The spinnerette of FIGS. 10 and l 1 is exemplary only, it being obvious to those skilled in the art that any suitable orifice configuration may be employed as obtainable by use of the building block technique for forming the spinnerettes as described above.

Thus, the collimated hole structure of the present invention is provided with passages which have non-regular cross sections such as T, L, S, I, star, trilobal, various non-symmetrical, etc. sections which may be made up from a plurality of preselected regular sections such as square, triangular, other polyhedral, L-shaped, etc. sections. Further, the invention comprehends making up regular section passages such as hexagonal section passages by utilizing a plurality of regular section rods such as triangular rods. The term regular as used herein comprehends geometric configurations of substantially symmetrical configuration as illustrated above. In accordance with the invention, the rods need merely be adaptable to be assembled in a building block assembly type of process, as further discussed above, to permit the final arrangement of the constricted rods in the desired passage configuration. The use of the non-regular collimated hole structures and collimated hole structures made by the building block method may have many other practical applications, as will be obvious to those skilled in the art.

While we have shown and described certain embodiments of our invention, it is to be understood that it is capable of many modifications. Changes, therefore, in the construction and arrangement may be made without departing from the spirit and scope of the invention as defined in the appended claims.

We claim:

1. A method of forming a collimated hole structure having at least one passage therein of a preselected cross section comprising the steps of:

a. bundling a plurality of preselected cross sectioned rods of first and second materials in a preselected pattern, at least two of the second material rods in longitudinal contact with each other defining a cross section different than the cross section of each individual second material rod, the first material rods substantially surrounding the second material rods;

b. constricting the bundle to reduce the rods to a preselected cross section and unifying the first material rods to form a substantially monolithic body; and

c. removing the second material rods to define at least one longitudinal passage in the body.

2. The method of forming a collimated hole structure of claim 1 wherein all the rods are bundled by endwise insertion into a tubular outer sheath.

3. The method of forming a collimated hole structure of claim 1 wherein the second material rods are unified by said constriction to define a continuous passage cross section upon removal thereof from the body.

4. The method of forming a collimated hole structure of claim 1 wherein said bundle is constricted by draw- 5. The method of forming a collimated hole structure of claim 1 wherein the rods are bundled by endwise insertion into a tubular outer sheath and spacers are inserted between the outermost rods and the sheath.

6. The method of forming a collimated hole structure of claim 1 wherein said spacers are formed of the same material as the first material rods to become unified therewith and form a portion of the body.

7. The method of forming a collimated hole structure of claim 1 wherein the bundle includes an outer sheath formed of the same material as the first material rods to become unified therewith and form a portion of the body.

8. The method of forming a collimated hole structure of claim 1 wherein the second material rods are removed from the body by dissolution.

9. The method of forming a collimated hole structure of claim 1 wherein the structure is cut to define spaced surfaces through which the passages open in the formed collimated hole structure. 

1. A method of forming a collimated hole structure having at least one passage therein of a preselected cross section comprising the steps of: a. bundling a plurality of preselected cross sectioned rods of first and second materials in a preselected pattern, at least two of the second material rods in longitudinal contact with each other defining a cross section different than the cross section of each individual second material rod, the first material rods substantially surrounding the second material rods; b. constricting the bundle to reduce the rods to a preselected cross section and unifying the first material rods to form a substantially monolithic body; and c. removing the second material rods to define at least one longitudinal passage in the body.
 1. A method of forming a collimated hole structure having at least one passage therein of a preselected cross section comprising the steps of: a. bundling a plurality of preselected cross sectioned rods of first and second materials in a preselected pattern, at least two of the second material rods in longitudinal contact with each other defining a cross section different than the cross section of each individual second material rod, the first material rods substantially surrounding the second material rods; b. constricting the bundle to reduce the rods to a preselected cross section and unifying the first material rods to form a substantially monolithic body; and c. removing the second material rods to define at least one longitudinal passage in the body.
 2. The method of forming a collimated hole structure of claim 1 wherein all the rods are bundled by endwise insertion into a tubular outer sheath.
 3. The method of forming a collimated hole structure of claim 1 wherein the second material rods are unified by said constriction to define a continuous passage cross section upon removal thereof from the body.
 4. The method of forming a collimated hole structure of claim 1 wherein said bundle is constricted by drawing.
 5. The method of forming a collimated hole structure of claim 1 wherein the rods are bundled by endwise insertion into a tubular outer sheath and spacers are inserted between the outermost rods and the sheath.
 6. The method of forming a collimated hole structure of claim 1 wherein said spacers are formed of the same material as the first material rods to become unified therewith and form a portion of the body.
 7. The method of forming a collimated hole structure of claim 1 wherein the bundle includes an outer sheath formed of the same material as the first material rods to become unified therewith and form a portion of the body.
 8. The method of forming a collimated hole structure of claim 1 wherein the second material rods are removed from the body by dissolution. 